Hole saw

ABSTRACT

A hole saw includes a substantially cylindrical body defining a cutting end and an axis of rotation. The hole saw also includes first and second apertures formed through the body and spaced from the cutting end such that a portion of the body extends between the cutting end and both the first and second apertures. The first and second apertures are both configured to receive a tool for removing work piece plugs from within the cylindrical body. The first aperture is axially spaced from the cutting end a first distance. The second aperture is axially spaced from the cutting end a second distance that is greater than the first distance. The first aperture and the second aperture are separated by a portion of the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/143,613, filed Sep. 27, 2018, which is a continuation of U.S.application Ser. No. 15/407,005, filed Jan. 16, 2017, now U.S. Pat. No.10,086,445, which is a continuation of U.S. patent application Ser. No.13/945,643, filed Jul. 18, 2013, now U.S. Pat. No. 9,579,732, whichclaims priority to U.S. Provisional Patent Application No. 61/673,124,filed Jul. 18, 2012, U.S. Provisional Patent Application No. 61/717,389,filed Oct. 23, 2012, and U.S. Provisional Patent Application No.61/784,172, filed Mar. 14, 2013, the contents of each of which areincorporated by reference herein.

BACKGROUND

The present invention relates to power tool accessories, and morespecifically, to hole saws.

A hole saw is a type of circular saw with a cylindrical, cup-like bodythat is rotated about a central axis in order to cut a cylindrical plugfrom a work piece, thereby forming a circular aperture in the workpiece. The plug, or core, of the work piece is received within thecup-like body as the hole saw progresses through the work piece. Undercertain conditions, the plug can become trapped within the body,necessitating manual removal of the plug by the user.

SUMMARY

In one embodiment, the invention provides a hole saw including acylindrical body disposed along an axis of rotation with a side wallextending axially from a cap end to a cutting end. The cutting endincludes a plurality of cutting teeth. A cap includes a rim portionseated on the cap end and an axially extending portion extending intothe cylindrical body from the cap end. The side wall defines an apertureincluding a first slot portion and a second slot portion disposed closerto the cap end than the first slot portion. A wall of the second slotportion nearest the cap end is between approximately 0.010 inches andapproximately 0.120 inches axially offset from the axially extendingportion of the cap.

In another embodiment the invention provides a hole saw. A cylindricalbody is disposed along an axis of rotation and includes a side wallextending axially from a cap end to a cutting end. The cutting endincludes a plurality of cutting teeth. A cap includes a rim portionseated on the cap end and an axially extending portion extending intothe cylindrical body from the cap end. The side wall defines an apertureincluding a first slot portion oriented substantially perpendicular tothe axis and a second slot portion disposed closer to the cap end thanthe first slot portion. A wall of the second slot portion nearest thecap end is between approximately 0.010 inches and approximately 0.120inches axially offset from the axially extending portion of the cap. Aconnecting slot portion connects the first slot portion and the secondslot portion.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a hole saw according to a firstembodiment of the invention.

FIG. 2 is a side view of the hole saw of FIG. 1.

FIG. 3 is a planar view of a cylindrical body of the hole saw of FIG. 1.

FIG. 4 is a top view of the hole saw of FIG. 1.

FIG. 5 is a perspective view of a hole saw according to anotherembodiment of the invention.

FIG. 6 is a side view of a first aperture of the hole saw of FIG. 5.

FIG. 7 is a side view of a second aperture of the hole saw of FIG. 5.

FIG. 8 is a top view of the hole saw of FIG. 5.

FIG. 9 is a side view of a third aperture of the hole saw of FIG. 5.

FIG. 10 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 11 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 12 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 13 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 14 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 15 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 16 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 17 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

FIG. 18 is a planar view of a cylindrical body of a hole saw accordingto another embodiment of the invention.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1-18 illustrate a power tool accessory, such as, for example, ahole-saw, for operation with a power tool (e.g., a drill, adriver-drill, a screwdriver, and the like). In some embodiments, thepower tool accessory is operable to cut holes of different sizes in awork piece and/or to remove plugs from the work piece. Each of theembodiments of the invention described below includes a cylindrical bodydefining at least one slot or aperture (e.g., a pair of slots orapertures). Hole saws including any number (e.g., one, two, three, ormore) of the disclosed slots or apertures, and variations thereof, arewithin the scope of the invention.

FIGS. 1-4 illustrates an embodiment of a power tool accessory, and morespecifically, a hole saw 10. The hole saw 10 includes a cylindrical body14 disposed along an axis of rotation 18. The cylindrical body 14 isdefined by a side wall 22 that extends between a cap end 26 and acutting end 30. As shown in FIG. 1, the cutting end 30 includes cuttingteeth 34. Each of the teeth 34 is defined by a leading edge 38 and atrailing edge 42.

As shown in FIG. 3, elongated apertures 46 are defined within the sidewall 22. Each elongated aperture 46 is defined by a first slot portion50 and a second slot portion 54, each orientated substantiallyperpendicular to the axis 18. The first slot portion 50 is axiallydisposed closer to the cutting end 30, and the second slot portion 54 isdisposed closer to the cap end 26. The first slot portion 50 is offsetrelative to the second slot portion 54. A connecting slot portion 58connects the first slot portion 50 and the second slot portion 54. Theconnecting slot portion 58 is at an angle relative to the cap end 26 andthe cutting end 30. The first slot portion 50, the second slot portion54, and the connecting slot portion 58 all have substantially the samewidth, though in other embodiments they may have different widths. Thesecond slot portion 54 includes an upper wall 55 that is substantiallyparallel to the cap end 26 and is located at a maximum distance D ofapproximately 0.2 inches from the cap end 26. Alternatively, the upperwall 55 of the second slot portion 54 may be flush with the cap end 26such that distance D is zero, or the second slot portion 54 may extendthrough a cap (not shown). The apertures 46 are configured to receive atool (not shown) for removing plugs from within the cylindrical body 14.

As illustrated in FIG. 3, the cap end 26 defines semi-circular slots 62configured to receive a plug-removing tool (not shown).

Referring to FIG. 2, a cap 66 is coupled to the cap end 26 of thecylindrical body 14. The cap 66 has substantially the same diameter asthe cylindrical body 14 and is welded to the cap end 26 with asubstantially continuous weld between the semi-circular slots 62. Thecap 66 includes a rim portion 70 that seats on the cap end 26 and anaxially extending portion 74 that extends into the cap end 26 of thecylindrical body. The rim portion 70 is substantially perpendicular tothe axially extending portion 74. As shown in FIG. 4, the cap 66 definesa main aperture 78 centered about the axis 18 and configured to receivea mandrel or equivalent tool (not shown). A plurality of holes 82 aredefined in the cap 66 and surround the main aperture 78. The pluralityof holes 82 are circumferentially arranged about the axis 18.

FIGS. 5-9 illustrate another embodiment of a hole saw 84. The hole saw84 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein. Referring to FIG. 5,the hole saw 84 includes a cylindrical body 88 and a cap 92. Thecylindrical body 88 includes a side wall 96 having a first aperture 100,a second aperture 104, and a third aperture 108. The apertures 100, 104,108 are configured to receive a tool (not shown) for removing the plugsfrom within the cylindrical body 88.

As shown in FIG. 6, the first aperture 100 is defined by a first slotportion 112 and a second slot portion 116. The first slot portion 112and the second slot portion 116 are each orientated substantiallyperpendicular to the axis 18. A connecting slot portion 118 connects thefirst slot portion 112 and the second slot portion 116. The second slotportion 116 includes an upper wall 117 that is substantially parallel tothe cap end 92 and is located at a maximum distance D of approximately0.2 inches from the cap end 92. Alternatively, the upper wall 117 of thesecond slot portion 116 may be flush with the cap end 92 such thatdistance D is zero, or the second slot portion 116 may extend throughthe cap 92 (FIG. 5).

As shown in FIG. 7, the second aperture 104 is defined by a sidewallportion 120 and a cap portion 124. The sidewall portion 120 extendsthrough the side wall 96 and terminates at an edge 128 that issubstantially perpendicular to the axis 18. The cap portion 124 extendsthrough the cap 92 and terminates at a semi-circular edge 132 as shownin FIG. 8.

Referring to FIG. 9, the third aperture 108 includes a first slotportion 136, a second slot portion 140, a connecting slot portion 144,and a vertical slot portion 148. The first slot portion 136 and thesecond slot portion 140 are each oriented substantially perpendicular tothe axis 18 and are connected by the connecting slot portion 144. Thevertical slot portion 148 extends from the second slot portion 140through the cap 92 and terminates at a semi-circular edge 152 within thecap 92 as shown in FIG. 8.

The cap 92 is welded to the body 88, with a substantially continuouswelds interrupted by the cap portion 124 of the second aperture 104 andthe vertical slot portion 148 of the third aperture.

FIG. 10 illustrates yet another embodiment of a hole saw 156. The holesaw 156 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein.

Referring to FIG. 10, the hole saw 156 includes a cylindrical body 160having a side wall 164 extending between a cap end 168 and a cutting end172. The cap end 168 defines a semi-circular slot 170 configured toreceive a plug-removing tool (not shown).

A pair of elongated apertures 174 are defined within the side wall 164.Each aperture 174 is configured to receive a tool (not shown) forremoving work piece plugs from within the cylindrical body 160. Eachelongated aperture 174 is defined by a first slot portion 178 and asecond slot portion 182. The first slot portion 178 is orientedsubstantially perpendicular to the axis 18. The second slot portion 182connects to the first slot portion 178 and is oriented at an angle 0relative to the axis 18. In the illustrated embodiment, the angle 0 isbetween approximately 14.5 degrees and approximately 15.5 degrees, butother embodiments may include other orientations. The first slot portion178 and the second slot portion 182 have substantially the same width184.

FIG. 11 illustrates yet another embodiment of a hole saw 190. The holesaw 190 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein.

As shown in FIG. 11, the hole saw 190 includes a cylindrical body 194having a side wall 198 extending between a cap end 202 and a cutting end206. A pair of elongated apertures 210 are defined within the side wall214. The elongated apertures 210 are configured to receive a tool (notshown) for removing plugs from within the cylindrical body 194. Eachelongated aperture 210 is defined by a first slot portion 218, a secondslot portion 222, and a third slot portion 226, each orientedsubstantially perpendicular to the axis 18. The first slot portion 218is disposed closer to the cutting end 206, and the third slot portion226 is disposed closer to the cap end 202. The second slot portion 222is disposed between the first slot portion 218 and the third slotportion 226. The third slot portion 226 includes an upper wall 227 thatis substantially parallel to the cap end 202. The upper wall 227 isoffset a distance B from the second slot portion 222. In the illustratedembodiment, distance B is between less than half of an axial height ofthe aperture 210. The upper wall 227 is located at a maximum distance Dof approximately 0.2 inches from the cap end 202. Alternatively, theupper wall 227 of the third slot portion 226 may be flush with the capend 202 such that distance D is zero, or the third slot portion 226 mayextend through a cap (not shown) coupled to the cap end 202.

A first connecting slot portion 230 connects the first slot portion 218and the second slot portion 222. The first connecting slot portion 230is oriented an angle 0 relative to the cap end 202 and the cutting end206. In the illustrated embodiment, the angle 0 is between approximately50.2 degrees and approximately 51.2 degrees, but other embodiments mayinclude other orientations.

A second connecting slot portion 234 connects the second slot portion222 and the third slot portion 226. The second connecting slot portion234 is oriented at an angle a relative to the cap end 202 and thecutting end 206. In the illustrated embodiment, the angle a is betweenapproximately 31.3 degrees and approximately 32.3 degrees, but otherembodiments may include other angle ranges.

FIG. 12 illustrates yet another embodiment of a hole saw 238. The holesaw 238 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein.

As shown in FIG. 12, the hole saw 238 includes a cylindrical body 242having a side wall 246 extending between a cap end 250 and a cutting end254. A pair of elongated apertures 258 are defined within the side wall246. Each elongated aperture 258 is defined by a first slot portion 262and a second slot portion 266, each orientated substantiallyperpendicular to the axis 18. The first slot portion 262 iscircumferentially disposed closer to the cutting end 254, and the secondslot portion 266 is disposed closer to the cap end 250, whereby thefirst slot portion 262 is offset relative to the second slot portion266. A connecting slot portion 270 connects the first slot portion 262and the second slot portion 266. The connecting slot portion 270 isoriented at an angle co relative to the cap end 250 and the cutting end254. In the illustrated embodiment, the angle co is betweenapproximately 50.3 degrees and approximately 51.3 degrees, but otherembodiments may include other angle ranges. The first slot portion 262,the second slot portion 266, and the connecting slot portion 270 allhave substantially the same width 274. The second slot portion 266includes an upper wall 278 that is substantially parallel to the cap end250 and is located at a maximum distance D of approximately 0.2 inchesfrom the cap end 250. Alternatively, the upper wall 278 of the secondslot portion 266 may be oriented flush with the cap end 250 such thatdistance D is zero, or the second slot portion 266 may extend through acap (not shown) coupled to the cap end 250. The apertures 258 areconfigured to receive a tool (not shown) for removing plugs from withinthe cylindrical body 242.

FIG. 13 illustrates yet another embodiment of a hole saw 278. The holesaw 278 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein.

As shown in FIG. 13, the hole saw 278 includes a cylindrical body 282having a side wall 286 extending between a cap end 290 and a cutting end294. A pair of elongated apertures 298 are defined within the side wall286. Each elongated aperture 298 is defined by a first slot portion 302and a second slot portion 306. The first slot portion 302 is disposedcloser to the cutting end 294, and the second slot portion 306 isdisposed closer to the cap end 290. The second slot portion 306 includesan upper wall 310 orientated substantially parallel to the cap end 290,and a radial wall 314 extends from the upper wall 310. The upper wall310 is located at a maximum distance D of approximately 0.2 inches fromthe cap end 290. Alternatively, the upper wall 310 of the second slotportion 306 may be oriented flush with the cap end 290 such thatdistance D is zero, or the second slot portion 306 may extend through acap (not shown) coupled to the cap end 290.

Referring to FIG. 13, the first slot portion 302 includes an upper wall318 and a lower wall 322, each oriented substantially perpendicular tothe axis 18. A connecting slot portion 326 connects the first slotportion 302 and the second slot portion 306 and includes a first wall330 and a second wall 334. The radial wall 314 connects to the firstwall 330, which connects to the lower wall 322. The second wall 334extends between the upper wall 310 and the upper wall 318. The firstwall 330 is oriented at an angle 1 relative to the cap end 290 and thecutting end 294. In the illustrated embodiment, the angle 1 is betweenapproximately 69.5 degrees and approximately 70.5 degrees, but otherembodiments may include other angle ranges. The second wall 334 isoriented at an angle μ relative to the cap end 290 and the cutting end294. In the illustrated embodiment, the angle μ is between approximately50.1 degrees and approximately 51.1 degrees, but other embodiments mayinclude other angle ranges.

FIG. 14 illustrates yet another embodiment of a hole saw 338. The holesaw 338 has substantial similarities to the hole saws 10 and 156described with respect to FIGS. 1-4 and 10, and only those aspects thatdiffer from the embodiments of FIGS. 1-4 and 10 will be describedherein.

As shown in FIG. 14, the hole saw 338 includes a cylindrical body 342having a side wall 346 extending between a cap end 350 and a cutting end354. The side wall 346 includes a first pair of elongated apertures 358and a second pair of elongated apertures 362. The first pair ofelongated apertures 358 are disposed closer to the cap end 350, and thesecond pair of elongated apertures 362 are disposed closer to thecutting end 354. Each of the first pair of apertures 358 includes afirst slot portion 366 and second slot portion 370.

The first slot portion 366 is oriented substantially perpendicular tothe axis 18. The second slot portion 370 extends from the first slotportion 366 and is oriented at an angle co relative to the cap end 350and the cutting end 354. In the illustrated embodiment, the angle co isbetween approximately 69.5 degrees and approximately 70.5 degrees, butother embodiments may include other angle ranges. The second slotportion 370 includes an upper wall 374 that is substantially parallel tothe cap end 350. The upper wall 374 is offset a distance B from thelower slot portion 366. In the illustrated embodiment, distance B isless than half of an axial height of the aperture 358. The upper wall374 is located at a maximum distance D of approximately 0.2 inches fromthe cap end 350. Alternatively, the upper wall 374 of the second slotportion 370 may be flush with the cap end 350 such that distance D iszero, or the second slot portion 370 may extend through a cap (notshown) coupled to the cap end 350. The first slot portion 366 and thesecond slot portion 370 have substantially the same width 378.

Each of the second pair of apertures 362 is defined by a first slotportion 382 oriented substantially perpendicular to the axis 18. Thefirst pair of apertures 358 and the second pair of apertures 362 aregenerally aligned in the same position and orientation relative to theaxis 18, though in other embodiments they may be staggered or in otherorientations.

FIG. 15 illustrates yet another embodiment of a hole saw 386. The holesaw 386 has substantial similarities to the hole saw 10 described withrespect to FIGS. 1-4, and only those aspects that differ from theembodiments of FIGS. 1-4 will be described herein.

As shown in FIG. 15, the hole saw 386 includes a cylindrical body 390having a side wall 394 extending between a cap end 398 and a cutting end402. A pair of elongated apertures 410 are defined within the side wall394. Each elongated aperture 410 is defined by a first slot portion 414and a second slot portion 418, each orientated substantiallyperpendicular to the axis 18. The first slot portion 414 is disposedcloser to the cutting end 402, and the second slot portion 418 isdisposed closer to the cap end 398. A connecting slot portion 422connects the first slot portion 414 and the second slot portion 418 andis oriented at an angle a relative to the cap end 398 and the cuttingend 402. In the illustrated embodiment, the angle a is betweenapproximately 60 degrees and approximately 80 degrees, more specificallyapproximately 70 degrees, but other embodiments may include otherangles. The connecting slot portion 422 includes a first wall 423 andsecond wall 424. The elongated aperture 410 has a circumferential widthA, measured in a direction parallel to the cap end 398 and cutting end402. In the illustrated embodiment, the circumferential width A isbetween approximately 1.250 inches and approximately 2.150 inches, morespecifically between approximately 1.475 inches and approximately 1.925inches, and even more specifically, approximately 1.700 inches. Acircumferential width A within these ranges provides for greater accessto a user when removing a work piece plug from the hole saw 386.

The second slot portion 418 includes an upper wall 426 orientatedsubstantially perpendicular to the axis 18, a lower wall 427 orientedsubstantially perpendicular to the axis 18, a side wall 428, and aradial wall 430 that extends from the upper wall 426. The radial wall430 connects to the first wall 423, which connects to the lower wall438. The second wall 424 connects to the lower wall 427, which connectsto the side wall 428. The upper wall 426 and lower wall 427 are axiallyseparated by a slot height B. In the illustrated embodiment, the slotheight B is between approximately 0.018 inches and approximately 0.038inches, more specifically approximately 0.028 inches. Having slot heightB within this range of values provides for optimal removal of deep workpiece plugs within the hole saw 386.

A slot width C of the second slot portion 418, measured in a directionparallel to the cap end 398, is between approximately 0.305 inches andapproximately 0.805 inches, more specifically, between approximately0.430 inches and approximately 0.680 inches, and even more specifically,approximately 0.555 inches. A slot width C within these ranges of valuesallows for a greater range of tools to be inserted into the slot inorder to remove a work piece plug. The upper wall 426 is located at amaximum distance D of approximately 0.2 inches from the cap end 398. Theupper wall 426 is located an axial offset E from a depth 432 of anaxially extending portion of a cap (e.g., the axially extending portion74 of the cap 66 described with respect to FIG. 2). In the illustratedembodiment, the axial offset E is between approximately 0.051 inches andapproximately 0.126 inches, more specifically between approximately0.072 inches and approximately 0.108 inches, and even more specifically,approximately 0.090 inches. Having an axial offset E within this rangeof values provides for easier removal of deep work piece plugs fromwithin hole saw 386. Alternatively, the upper wall 426 of the secondslot portion 418 may be oriented flush with the cap end 398 such thatdistance D is zero, or the second slot portion 418 may extend through acap (not shown) coupled to the cap end 398.

The first slot portion 414 includes an upper wall 434 and a lower wall438, each oriented substantially perpendicular to the axis 18. The upperwall 434 is disposed a distance F from the cutting end 402. In theillustrated embodiment, distance F is between approximately 0.541 inchesand approximately 0.895 inches, more specifically between approximately0.627 inches and approximately 0.809 inches, and even more specifically,approximately 0.718 inches. Having distance F within this range ofvalues allows a user to apply more axially-aligned force when removing aplug from the hole saw 386. Each aperture 410 is configured to receive atool (not shown) for removing work piece plugs from within thecylindrical body 390.

FIG. 16 illustrates yet another embodiment of a hole saw 442. The holesaw 442 has substantial similarities to the hole saw 10, 156, and 338described with respect to FIGS. 1-4, 10, and 14, and only those aspectsthat differ from the embodiments of FIGS. 1-4, 10, and 14 will bedescribed herein.

As shown in FIG. 16, the hole saw 442 includes a cylindrical body 446having a side wall 450 extending between a cap end 454 and a cutting end458. The cutting end 458 includes a plurality of cutting teeth 462. Theplurality of cutting teeth 462 may be coated with an abrasive coating,e.g., diamond grit.

Elongated apertures 466 are defined within the side wall 450. Eachelongated aperture 466 is defined by a first slot portion 470 and asecond slot portion 474. The first slot portion 470 is orientedsubstantially perpendicular to the axis 18. The second slot portion 474connects to the first slot portion 470 and is oriented at an angle Rrelative to the cap end 454 and the cutting end 458. In the illustratedembodiment, the angle (L is between approximately 73.5 degrees andapproximately 74.5 degrees, but other embodiments may include otherranges. The first slot portion 470 and the second slot portion 474 havesubstantially the same width 478. The second slot portion 474 includesan upper wall 482 that is substantially parallel to the cap end 454 andis located at a maximum distance D of approximately 0.2 inches from thecap end 454. Alternatively, the upper wall 482 of the second slotportion 474 may be oriented flush with the cap end 454 such thatdistance D is zero, or the second slot portion 474 may extend through acap (not shown) coupled to the cap end 454. Each aperture 466 isconfigured to receive a tool (not shown) for removing work piece plugsfrom within the cylindrical body 446.

FIG. 17 illustrates yet another embodiment of a hole saw 486. The holesaw 486 has substantial similarities to the hole saws 10 and 386described with respect to FIGS. 1-4 and 15, and only those aspects thatdiffer from the embodiments of FIGS. 1-4 and 15 will be describedherein.

As shown in FIG. 17, the hole saw 486 includes a cylindrical body 490having a side wall 494 extending between a cap end 498 and a cutting end502. The cutting end 502 includes a plurality of cutting teeth 506. Theplurality of cutting teeth 506 may be coated with an abrasive coating,e.g., diamond grit.

The side wall 494 defines a plurality of elongated apertures 510. Eachelongated aperture 510 is defined by a first slot portion 514 and asecond slot portion 518, each orientated substantially perpendicular tothe axis 18. The first slot portion 514 is disposed closer to thecutting end 502, and the second slot portion 518 is disposed closer tothe cap end 498. A connecting slot portion 522 connects the first slotportion 514 and the second slot portion 518 and is oriented at an acuteangle relative to the cap end 498 and the cutting end 502. Theconnecting slot portion includes a first wall 523 and second wall 524.

The second slot portion 518 includes an upper wall 526 orientatedsubstantially perpendicular to the axis 18, a lower wall 527 orientedsubstantially perpendicular to the axis 18, a side wall 528, and aradial wall 530 that extends from the upper wall 526. A distance Bdefined between the upper wall 526 and the lower wall 527 is less thanhalf of an axial height of the aperture 510. The upper wall 526 islocated at a maximum distance D of approximately 0.2 inches from the capend 498. Alternatively, the upper wall 526 of the second slot portion518 may be oriented flush with the cap end 498 such that distance D iszero, or the second slot portion 518 may extend through a cap (notshown) coupled to the cap end 498. The first slot portion 514 includesan upper wall 534 and a lower wall 538, each oriented substantiallyperpendicular to the axis 18. The radial wall 530 connects to the firstwall 523, which connects to the lower wall 538. The second wall 524connects to the lower wall 527, which connects to the side wall 528.Each aperture 510 is configured to receive a tool (not shown) forremoving work piece plugs from within the cylindrical body 490.

FIG. 18 illustrates yet another embodiment of a hole saw 542. The holesaw 542 has substantial similarities to the hole saw 10, 156, 338, and442 described with respect to FIGS. 1-4, 10, 14 and 16, and only thoseaspects that differ from the embodiments of FIGS. 1-4, 10, 14 and 16will be described herein.

As shown in FIG. 18, the hole saw 542 includes a cylindrical body 546having a side wall 550 extending between a cap end 554 and a cutting end558. The cutting end 558 includes a plurality of cutting teeth 562. Theplurality of cutting teeth 562 may be coated with an abrasive coating,e.g., diamond grit.

Elongated apertures 566 are defined within the side wall 550. Eachaperture 566 is configured to receive a tool (not shown) for removingwork piece plugs from within the cylindrical body 446. Each elongatedaperture 566 is defined by a first slot portion 570 and a second slotportion 574. The elongated apertures 566 each have a circumferentialwidth A, measured in a direction parallel to the cap end 554 and cuttingend 558. In the illustrated embodiment, the circumferential width A isbetween approximately 0.595 inches and approximately 0.895 inches, morespecifically between approximately 0.670 inches and approximately 0.820inches, and even more specifically, approximately 0.745 inches. Acircumferential width A within these ranges provides for greater accessto a user when removing a work piece plug from the hole saw 542.

The first slot portion 570 is oriented substantially perpendicular tothe axis 18. The second slot portion 574 connects to the first slotportion 570 and is oriented at an angle 1c relative to an end wall 576of the first slot portion 570, where the end wall 576 is oriented atapproximately 15 degrees relative to the axis 18. In the illustratedembodiment, the angle 1c is between approximately 25.5 degrees andapproximately 26.5 degrees, but other embodiments may include otherranges.

A slot width C of the second slot portion 574, measured in a directionparallel to the cap end 554, is between approximately 0.280 inches andapproximately 0.480 inches, more specifically, between approximately0.330 inches and approximately 0.430 inches, and even more specifically,approximately 0.380 inches. A slot width C within these ranges of valuesallows for a greater range of tools to be inserted into the slot inorder to remove a work piece plug.

The second slot portion 574 includes an upper wall 582 that is parallelto the cap end 554 and is located at a maximum distance D ofapproximately 0.188 inches from the cap end 554. The upper wall 582 islocated at an axial offset E from a depth 584 of an axially extendingportion of a cap (e.g., the axially extending portion 74 of the cap 66described with respect to FIG. 2). In the illustrated embodiment, theaxial offset E is between approximately 0.010 inches and approximately0.120 inches, more specifically between approximately 0.030 inches andapproximately 0.090 inches, and even more specifically, approximately0.050 inches. Having an axial offset E within this range of valuesprovides for easier removal of deep work piece plugs from within holesaw 542. Alternatively, the upper wall 582 of the second slot portion574 may be oriented flush with the cap end 554 such that distance D iszero, or the second slot portion 574 may extend through a cap (notshown) coupled to the cap end 554.

The first slot portion 570 includes an upper wall 588 and a lower wall592, each oriented substantially perpendicular to the axis 18. The upperwall 588 is disposed a distance F from the cutting end 558. In theillustrated embodiment, distance F is between approximately 0.050 inchesand approximately 0.895 inches, more specifically between approximately0.670 inches and approximately 0.820 inches, and even more specifically,approximately 0.745 inches. Having distance F within these ranges ofvalues allows a user to apply more axially-aligned force when removing aplug from the hole saw 542.

Although the invention has been described with reference to certainpreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects of the invention asdescribed.

Thus, the invention provides, among other things, a hole saw. Variousfeatures and advantages of the invention are set forth in the followingclaims.

What is claimed is:
 1. A hole cutter comprising: a substantially cylindrical blade body having a smooth outer wall, the blade body defining a cutting edge and a longitudinal axis; a first aperture formed through the blade body and spaced from the cutting edge such that a portion of the blade body extends between the cutting edge and the first aperture, the first aperture configured to receive therethrough a lever for removing a work piece slug from an interior of the blade body and defining a first fulcrum configured for engaging the lever and for levering the slug out of the interior of the blade body by applying a sufficient levering force against the first fulcrum to lever the slug towards the cutting edge; a second distinct aperture formed through the blade body and spaced from the cutting edge such that a portion of the blade body extends between the cutting edge and the second aperture, the second aperture configured to receive therethrough a lever for removing a work piece slug from an interior of the blade body and defining a second fulcrum configured for engaging the lever and for levering the slug out of the interior of the blade body by applying a sufficient levering force against the second fulcrum to lever the slug towards the cutting edge; wherein the first fulcrum is axially spaced from the cutting edge a first distance, the second fulcrum is axially spaced from the cutting edge a second distance that is greater than the first distance, wherein the first fulcrum is defined by a substantially straight edge of the first aperture that is substantially parallel to the cutting edge, wherein at least a portion of the first aperture and at least a portion of the second aperture are aligned along a line substantially parallel to the longitudinal axis and the first fulcrum and the second fulcrum are aligned along the line substantially parallel to the longitudinal axis, and wherein at least one of the first aperture and the second aperture is bounded by a bottom edge axially spaced a third distance from the cutting edge, a top edge spaced a fourth distance from the cutting edge greater than the third distance, and a side edge connecting the bottom edge to the top edge and oriented at an acute angle to the longitudinal axis of the blade body.
 2. The hole cutter of claim 1, wherein the second fulcrum is defined by a substantially straight edge of the second aperture that is substantially parallel to the cutting edge.
 3. The hole cutter of claim 2, wherein the top edge is substantially parallel to the bottom edge.
 4. The hole cutter of claim 1, wherein the top edge is a substantially straight edge that is substantially parallel to the cutting edge and that defines at least one of the first fulcrum and the second fulcrum, and the bottom edge is a substantially straight edge that is substantially parallel to the top edge.
 5. The hole cutter of claim 1, wherein each of the first aperture and the second aperture defines a minimum width to allow insertion of a plug-removing tool therethrough.
 6. The hole cutter of claim 1, wherein the second aperture is axially elongated.
 7. The hole cutter of claim 1, wherein the first and second fulcrums are defined by first and second edges of the first and second apertures that are curved, curvilinear, rectilinear, or a combination thereof.
 8. The hole cutter of claim 1, wherein the top edge comprises: a substantially straight edge comprising a first end and a distal second end; a first curved corner at the first end; and a second curved corner at the second end.
 9. The hole cutter of claim 1, wherein the cutting edge comprises a plurality of teeth disposed continuously around a circumference of the cutting edge.
 10. The hole cutter of claim 1, wherein the second aperture has a geometric shape that is distinct from that of the first aperture.
 11. The hole cutter of claim 1, wherein all of the first aperture and all of the second aperture are arranged on a same side of at least one plane that contains the longitudinal axis. 